Pop-up wipes dispensing system for substantially dry wipes

ABSTRACT

Pop-up dispensing systems for dispensing substantially dry wipes while minimizing “clumping” and “fallbacks”, or sticking of tacky, adhesive binder loaded wipes within the interior of the container body. The dispensing system includes a container having a container body forming an interior region, and a plurality of stacked substantially dry wipes or other substrates. The wipes may be loaded with an adhesive binder or other material. By selecting and providing particular characteristics relative to the cross-sectional area of the dispensing orifice (e.g., 22 cm 2  to 75 cm 2 ) and the separation force profile (e.g., 1 gf/cm 2  to 6 gf/cm 2 ), wipes which are loaded with an adhesive, tacky binder material can be dispensed one at a time, while minimizing clumping and fallbacks, and any tendency of the wipes to becoming stuck within the container body.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Patent Application Ser. No. 62/031,081, filed Jul. 30, 2014 and entitled “POP-UP WIPES DISPENSING SYSTEM”, the disclosure of which is incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention is generally related to pop-up dispensing systems for substantially dry wipes, for example, to dispensing systems containing wipes which may be folded in an interleaved pattern. In particular, the invention relates to dispensing systems for substantially dry wipes which provide improved pop-up dispensing characteristics, particularly for such substantially dry wipes. By substantially dry, it is meant that the wipe is not wet or moist to the touch, but is loaded, e.g., with an adhesive binder or other material that may be tacky.

2. Description of Related Art

The general use of nonwoven fabrics as a component in cleaning or dry dusting wipes is well known in the art. Substrates for cleaning and dusting products are commercially available which employ a combination of cleaning compositions, additives and multi-layer laminate substrates which include different layers of material to achieve good particle pick up performance.

It is also well known in the art to create pop-up dispensers for wet wipes such as baby wipes or dry wipes like facial tissues with stacks of interleaved wipes in a container. Pop-up dispensers function by providing a dispensing orifice, which is sized and configured so that in combination with a stack of wipes having a particular folding configuration, the upper portion of the adjacent following wipe is held within the dispensing orifice when the uppermost lead wipe is dispensed. These pop-up dispensers are designed such that during the removal action of the lead wipe from the container through the orifice, the following wipe is pulled by contact with the lead wipe and is elevated from the stack such that it partially protrudes through the orifice once the lead most wipe has been removed. In this manner the next uppermost wipe becomes the lead wipe, and is positioned for easy grasp by the consumer. Examples of these type of pop-up dispensers that allow the wipes to be provided either on a continuous roll with perforations therein or as separately folded wipes are described in U.S. Pat. No. 5,560,514 by Frazier, assigned to Kimberly-Clark Tissue Company. Examples of other dispensers for wet wipes, e.g., baby wipes, include U.S. Pat. No. 6,550,634 by Miguel and U.S. Pat. No. 6,960,349 by Shantz, both assigned to The Proctor & Gamble Company.

It is further known in the art to apply a tacky composition to a substrate to improve its particulate pick up performance. An adhesive, such as a binder may be applied to the surface of the wiping product. Alternatively, a mineral oil may be used on wiping products to increase the particulate pick up performance of the wipe.

The prior art does not teach how to create a pop-up dispenser system for a substantially dry wipe where the substantially dry wipe is tacky and well suited for cleaning applications, e.g., such as where good particle pick up performance is provided. The pop-up dispensing systems taught by the prior art are suitable for dry tissues or wipes (e.g., facial tissue boxes) or for wet wipes (e.g., baby wipes dispensers), although neither of these systems work well with substantially dry, tacky wipes.

For example, the inventors have found that putting substantially dry tacky wipes into a dry wipe dispenser can result in undesirable “roping” and/or “clumping”. In roping, the lead wipe does not fully separate from the following wipe as the lead wipe is pulled from the dispenser, leading to more than the single desired wipe being dispensed. In clumping, more than one wipe is similarly dispensed at a single time, where the following wipe may form a clump with the lead wipe (e.g., because of its tacky, adhesive characteristics, it may be difficult to separate and unfold such clumped wipes one from another). Alternatively, using a wet wipes dispenser for dispensing substantially dry, tacky wipes can result in wipes getting stuck within the dispenser, so that they cannot be easily pulled out by the consumer. Either alternative is unacceptable.

BRIEF SUMMARY OF THE INVENTION

In an embodiment, the present invention is directed to a pop-up dispensing system for dispensing substantially dry substrates, such as wipes. The system may include a container including a container body forming an interior region, a plurality of stacked substantially dry substrates (e.g., wipes) disposed within the interior region of the container, the stacked substrates being coated or impregnated with a desired material (e.g., a tacky adhesive binder, or other loading material). An upper panel of the container body may include a dispensing orifice through which a lead substrate of the plurality of stacked substrates can be pulled. The dispensing orifice may have a cross-sectional area of from 22 cm² to 75 cm². The stacked substrates may be stacked in a manner (e.g., relative to their overlap one with another) so as to exhibit a separation force profile of the lead substrate from a following substrate of from 1 gram of force per cm² (gf/cm²) to 6 gf/cm².

Another embodiment is directed to a pop-up dispensing system for dispensing substantially dry, tacky wipes. The system may include a container including a container body forming an interior region, a plurality of stacked substantially dry but tacky wipes that are coated or impregnated with a tacky adhesive binder, the stack of substrates being disposed within the interior region of the container in a manner such that pulling on a lead end of a lead wipe of the plurality of stacked wipes causes a following wipe of the plurality of wipes to also be pulled and to follow the lead wipe. A dispensing orifice is provided in an upper panel of the container body through which a lead wipe can be pulled. The dispensing orifice may have a cross-sectional area of from 22 cm² to 75 cm². The stacked wipes may be stacked in a manner so as to exhibit a separation force profile of the lead wipe from a following wipe of from 1 gf/cm² to 6 gf/cm², and an overlap distance relative to one another of from 5 mm to 50 mm.

Another embodiment is directed to a pop-up dispensing system for dispensing substantially dry, tacky wipes. The system may include a container including a container body forming an interior region, a plurality of stacked substantially dry, tacky that are coated or impregnated with a tacky adhesive binder, the stack of wipes being disposed within the interior region of the container and being interfolded with one another in a manner such that pulling on a lead end of a lead wipe of the plurality of stacked wipes causes a following wipe of the plurality of wipes to also be pulled and to follow the lead wipe. In one embodiment of the invention, the lead substrate pulls on the following substrate as it goes through the dispensing orifice so that it is substantially flat when the lead substrate is separated from the following substrate. In this embodiment, the lead substrate is dispensed and separated from the following substrate it is no longer folded and the user does not need to unfold the wipe before cleaning a surface. This dispensing system may dispense wipes that are substantially flat or fully unfolded and ready-to-use. A generally diamond shaped dispensing orifice may be provided in an upper panel of the container body through which a lead wipe can be pulled. The corners of the diamond may be rounded to better facilitate insertion of a user's fingers through the dispensing orifice to retrieve the lead wipe. The wipes may be stacked so that each wipe has a center pick point, so that the lead end of each wipe is vertically aligned below the dispensing orifice. Each following wipe may have an overlap distance relative to its adjacent lead wipe of from 5 mm to 50 mm, the separation force profile of the lead wipe from the following wipe may be from 1 gf/cm² to 6 gf/cm², and the dispensing orifice may have a cross-sectional area of from 22 cm² to 75 cm².

Further features and advantages of the present invention will become apparent to those of ordinary skill in the art in view of the detailed description of preferred embodiments below.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the drawings located in the specification. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a perspective view of an exemplary pop-up dispensing system for substantially dry wipes according to the present invention;

FIG. 2A is a perspective view of an exemplary pop-up dispensing system similar to that of FIG. 1, but including a differently configured dispensing orifice;

FIG. 2B is a perspective view of an exemplary pop-up dispensing system similar to that of FIG. 1, but including yet another differently configured dispensing orifice;

FIG. 3A is a perspective view of an exemplary pop-up dispensing system similar to that of FIG. 1, but including yet another differently configured dispensing orifice;

FIG. 3B is a perspective view of an exemplary pop-up dispensing system similar to that of FIG. 1, but including yet another differently configured dispensing orifice;

FIG. 3C is a perspective view of an exemplary pop-up dispensing system similar to that of FIG. 1, but including yet another differently configured dispensing orifice;

FIG. 4A is a schematic illustration of an exemplary Z-Z-Z stacking pattern;

FIG. 4B is a schematic illustration of another exemplary Z-Z-Z stacking pattern;

FIG. 4C is a schematic illustration of another exemplary Z-Z-Z stacking pattern;

FIG. 5A is a schematic illustration of an exemplary Z-V-Z stacking pattern;

FIG. 5B is a schematic illustration of another exemplary Z-V-Z stacking pattern;

FIG. 6A is a schematic illustration of an exemplary J fold pattern;

FIG. 6B is a schematic illustration of a plurality of J-folded wipes such as that of FIG. 6A stacked together;

FIG. 7A is a schematic illustration of an exemplary C fold pattern;

FIG. 7B is a schematic illustration of a plurality of C-folded wipes such as that of FIG. 7A stacked together;

FIG. 8A plots maximum load (i.e., separation force) against overlap between wipes for several half width (3.5 inches wide) tested samples;

FIG. 8B plots maximum load (i.e., separation force) against overlap between wipes for several full width (7 inches wide) tested samples;

FIG. 9 plots maximum load per area, in gf/cm², (i.e., referred to herein as the separation force profile) against overlap distance for various tested wipes; and

FIG. 10 plots the force profile for dispensing of a dry wipe (e.g., tissue), a wet wipe (e.g., baby wipe), as well as exemplary tacky substantially dry wipes.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS I. Definitions

Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner.

All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.

The term “comprising” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

The term “consisting essentially of” limits the scope of a claim to the specified materials or steps “and those that do not materially affect the basic and novel characteristic(s)” of the claimed invention.

The term “consisting of” as used herein, excludes any element, step, or ingredient not specified in the claim.

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “surfactant” includes one, two or more surfactants.

Unless otherwise stated, all percentages, ratios, parts, and amounts used and described herein are by weight.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.

II. Introduction

The present invention is directed to pop-up dispensing systems for dispensing substantially dry wipes or other substrates in a manner that a single substrate may be dispensed from the system and separated from the remaining stack of substrates within the container, without “roping” or “clumping” as the substrates are dispensed. In addition, the system may prevent substantially dry substrates loaded with an adhesive binder, which may be tacky, from becoming stuck to the surfaces of the container, making dispensing difficult, if not impossible as a practical matter. In an embodiment, the dispensing system includes a container having a container body forming an interior region, and a plurality of stacked substantially dry substrates. The substantially dry substrates may be loaded with an adhesive binder or other material. In an embodiment, the substrates are not loaded with water or aqueous solutions, as they are substantially dry to the touch. The inventors have found that by selecting and providing particular characteristics relative to the cross-sectional area of the dispensing orifice and the separation force profile, wipes which are loaded with an adhesive, tacky binder material can be dispensed one at a time, without roping or clumping, while also minimizing or preventing the wipes from becoming stuck within or to the container body.

As used herein, separation force profile refers to a measured or calculated force (e.g., grams of force) per overlap area (e.g., cm²) between two wipes. Overlap refers to the portion of two folded wipes where the lead wipe and following wipe are connected. Such a separation force profile may be calculated as the peak force measured when separating a wipe from a following wipe divided by the overlap distance of the two wipes times the width of the wipe. For example, for a peak force measurement of 0.193 lbf (87.6 gf), an overlap distance of 29 mm (2.9 cm) and a wipe width of 3.5 inches (8.89 cm), the separation force profile would be 87.6 gf/(2.9 cm×8.89 cm), or 3.4 gf/cm².

III. Exemplary Dispensers

FIG. 1 shows an exemplary pop-up dispensing system 100 for dispensing substantially dry wipes or other substrates. As shown, the system 100 may be configured so as to exhibit a relatively low profile (e.g., width and length greater than height), and may include a container defined by a container body 102. Container body 102 defines an interior region 104 (e.g., seen through dispensing orifice 106). Within interior region 104 are disposed a plurality of stacked substantially dry wipes 108. Wipes 108 are loaded (e.g., coated, impregnated, etc.) with a desired material (e.g., a tacky adhesive binder). Other materials may be loaded within each wipe 108, although as described above, the wipes may not be wet or moist to the touch, but may exhibit a dry (but perhaps tacky) feel on contact with a user's fingers. Dispensing orifice 106 may be defined through an upper panel 110 of container body 102, allowing a lead wipe of wipes 108 to be pulled, as desired.

Such substantially dry wipes are not readily dispensed from existing dispensing systems that are specifically designed and configured for use with either wet wipes (e.g., baby wipes), or for use with completely dry wipes or similar substrates (e.g., tissues). As described above, use of such dispensing systems with substantially dry but tacky wipes results in roping or clumping when attempting to dispense a single wipe at a time, or in unwanted adhesion and sticking of the wipes to the interior of the container body, one another, etc. In order to provide the ability to reliably dispense a single substantially dry wipe at a time, the dispensing orifice 106 may have a cross-sectional area from 22 cm² to 75 cm², and stacked wipes 108 may be stacked in a manner to exhibit a separation force profile of a lead wipe from a following wipe of from 1 gf/cm² to 6 gf/cm².

As shown in FIG. 1, container body 102 may be a generally rectangular prism in shape, although it will be appreciated that other shapes of container bodies may be provided in other embodiments (e.g., cube, cylindrical, oval geometry, etc.). In an embodiment, the container body may be formed from paperboard, e.g., a four or five paneled rectangular paperboard carton. Illustrated container body 102 includes five panels, including upper panel 110, opposed side panels 112, 114, a lower panel 116, and a fifth folding cover panel 118 different from upper panel 110 in which dispensing orifice 106 is formed. Such a cover panel 118 may fold over the dispensing orifice 106 of upper panel 110, acting as a lid so as to protect wipes 108 during storage, prior to the opening of the carton, when not in use, etc.

It will be appreciated that in other embodiments, no folding cover panel 118 attached to upper panel 110, side panel 114 (e.g., to the interface therebetween) may be provided. For example, a separate cover (not shown) could be provided that fits over at least dispensing orifice 106 of upper panel 110, or entire upper panel 110, so as to protect wipes 108 within interior 104 from dirt, dust, particulates, and other debris which may otherwise find their way into orifice 106 and onto wipes 108. For example, such a separate cover may snap over the corners and/or outer perimeter of upper panel 110, so as to cover dispensing orifice 106.

In the illustrated embodiment, cover panel 118 may include a protruding insert 120 having the same perimeter shape and size as that of dispensing orifice 106, so that insert 120 may press into orifice 106, effectively filling the cross-sectional space of orifice 106. Such an insert may further serve to seal and protect interior region 104, preventing entry of dirt, dust, or other debris. In an alternative embodiment of the invention, the inside surface of the cover panel 118 will a substantially flat surface, free from any protrusions or inserts which would cover the orifice 106.

Cover panel 118 is shown as further including a locking tab 122 extending from a front edge of panel 118. Locking tab 122 may be folded or bent downward as cover panel 118 is closed over upper panel 110, and inserted into corresponding receiving slot 124 which may be formed into front edge of upper panel 110, and/or into side panel 112. As shown, tab 122 and slot 124 may be aligned with one another, so that tab 122 is received into slot 124. Once received into slot 124, tab 122 may hold cover panel 118 closed over upper panel 110 until the user selectively disengages tab 122 from slot 124.

The carton (e.g., dispensing system 100) may be provided with cover panel 118 initially closed over upper panel 110, and may be opened by ripping perforations (e.g., surrounding locking tab 122) so as to release cover panel 118. Such rippable perforated tabs (not shown) could similarly be provided adjacent sides 113 and 115. In another embodiment, tab 122 may initially be secured to side 112, with cover panel 118 folded down over upper panel 110. Once opened, tab 122 may be inserted into slot 124 so that the carton may be secured closed. In the illustrated five panel embodiment the orifice 106 is on a different panel than the cover 118. The five panel container allows for lid closure, even after initially opening of the carton or container. The orifice may be designed specifically for the size, material, and overlap pattern of the wipes. The orifice is designed so that each wipe fully opens upon dispensing and the next wipe “pops up.” Alternatively, the dispensing may be similar to a standard dryer sheet container where the orifice is modified to create the appropriate surface area size and shape that enables efficient dispensing.

As seen in FIG. 1, in an embodiment, dispensing orifice 106 may be generally diamond shaped, in which the corners 126 a-126 d of the diamond are rounded, rather than angular to better facilitate insertion of a user's fingers through dispensing orifice 106 to retrieve a lead wipe of wipes 108. In the illustrated embodiment, latitudinal corners 126 b and 126 d (i.e., those corners defining the maximum width of orifice 106) further include a scalloped or scooped out portion 127 that extends the width of orifice 106 adjacent corners 126 b and 126 d beyond where it would extend if the linear perimeter portions 128 of orifice 106 continued until their intersection (128 a). Such a scalloped or scooped out arrangement increases the width of orifice 106, making it less likely that a user's knuckles (particularly a user's distal and proximal interphalangeal joints) will inadvertently catch on upper panel 110 at the perimeter of orifice 106.

FIGS. 2A and 2B illustrate alternative dispensing systems 100, similar to that of FIG. 1, but in which the dispensing orifice 106 a (FIG. 2A) or 106 b (FIG. 2B) has the same generally diamond shape, but with a reduced cross-sectional area as compared to that of FIG. 1. For example, dispensing orifice 106 a of FIG. 2A has a cross-sectional area that is about 5% smaller than that of FIG. 1, while dispensing orifice 106 b has a cross-sectional area that is about 10% smaller than that of FIG. 1.

FIG. 3A illustrates another dispensing system 100, also similar to that of FIG. 1, but with a differently shaped dispensing orifice 206. Dispensing orifice 206 exhibits a generally oval shape, modified by the inclusion of opposed width extensions 227 to the orifice 206. As shown, the oval may be oriented relative to upper panel 110 so that the longer dimension of the oval (i.e., its length) is aligned with the longitudinal length of upper panel 110, while the width of the oval (and extension 227) are aligned with the width of upper panel 110.

FIG. 3B illustrates another dispensing system 100, also similar to that of FIG. 1, but including a differently shaped dispensing orifice 306. Dispensing orifice exhibits a generally rectangular shape, with curved corners 326 a-326 d. As shown, one or more of the sides (e.g., sides 328) of orifice 306 may be outwardly curved, as shown. In the illustrated example, two opposed sides 328 are outwardly curved, while the other sides disposed therebetween are generally straight. Other variations are also possible. For example, all 4 sides could be outwardly curved, just the two longer sides could be outwardly curved, etc. One or more of the sides could be inwardly curved, etc.

FIG. 3C illustrates another dispensing system 100, also similar to that of FIG. 1, but including a differently shaped dispensing orifice 406, where the orifice is also formed into upper panel 110, but at a location other than being centered therein. For example, each of the dispensing orifices of FIGS. 1-3B are centered within upper panel 110, while dispensing orifice 406 is shown as being disposed near an upper end of panel 110, but still centered side-to-side within panel 110. Dispensing orifice 406 is illustrated as being generally triangular, in which the corners 426 a-426 c of the triangle are rounded. While triangular orifice 406 is shown as a right triangle, with perimeter sides 428 being parallel to the upper and rear edges of upper panel 110, and the hypotenuse oriented towards slot 124, it will be appreciated that other orientations and configurations of a triangular dispensing orifice are also within the scope of the present invention.

As various dispensing orifice geometries are shown and described, it will be appreciated that further modifications and variations are possible. The orifice may be of any desired shape, such as, but not limited to, circular, rectangular, diamond, triangular, oval, star shaped, flower shaped, etc. Diamond or oval shapes may be particularly preferred for providing particularly good ease of access to the lead wipe of wipes 108, while aiding in minimizing any roping tendency, clumping and sticking of the wipes to one another, sticking of tacky wipes within the container and about the orifice, catching of fingers etc. The diamond shape has been shown by the inventors' testing to be particularly good at minimizing roping, clumping, and sticking of wipes into the container, etc.

In an embodiment, the perimeter defining the boundaries of the orifice may be rigid, so as to not significantly alter its shape during use, as a wipe is dispensed therethrough. Furthermore, in an embodiment, the orifice does not include sharp edges or corners, which may instead be rounded. Such rounded edges may be preferred for preventing or minimizing catching of wipes as they are dispensed, or catching of fingers as they retrieve and navigate or thread a wipe through the orifice.

In any case, the dispensing orifice provides a cross-sectional area that facilitates quick and easy dispensing of a single wipe 108, without roping, clumping, and without the wipes undesirably sticking to one another or the container body as they are dispensed through the orifice. In an embodiment, the cross-sectional area of the dispensing orifice is at least 22 cm², from 22 cm² to 75 cm², from 22 cm² to 70 cm², from 35 cm² to 58 cm², or from 40 cm² to 48 cm².

The substantially dry wipes may be stacked and stored within the interior 104 of rigid dispensing container body 102, between lower and upper panels 116 and 110, respectively. The plurality of wipes 108 may be stacked in a manner so that pulling on a lead end of a lead wipe causes a following wipe of the plurality of wipes to also be pulled, following the lead wipe. In order to prevent roping, as the lead wipe is pulled through the dispensing orifice (e.g., orifice 106), the following wipe separates therefrom, with a lead end of the following wipe (which is now the lead wipe) extending from the dispensing orifice, ready to be easily grasped by the user. On occasion, the following wipe may fall back through the dispensing orifice, and with their fingers, the user may reach into the orifice to retrieve the lead end of the lead wipe.

In some embodiments, the wipes may be interleaved or interfolded (these terms may be used interchangeably herein) one with another. In other embodiments, wipes may be stacked one atop another, technically without any interleaving between adjacent wipes, but in which the wipes overlap one another to some degree. Such an overlap, particularly with wipes loaded with a tacky adhesive binder, may allow a following wipe to follow a lead wipe as the lead end of the lead wipe is pulled through the dispensing orifice. The lead wipe pulls on the following wipe as it passes through the dispensing orifice so that the lead wipe is substantially flat (i.e. unfolded) as it is separated from the following wipe. The wipe that is dispensed as the lead wipe may be fully unfolded and ready-to-use for cleaning.

The separation force profile per area of the stack of wipes 108 may be specifically tailored so as to provide the desired dispensing characteristics (e.g., minimization of roping, clumping, sticking within the container, etc.). For example, the separation force profile may be from 1 gf/cm² to 6 gf/cm², for example, 1 gf/cm², about 2 gf/cm², about 3 gf/cm², about 4 gf/cm², about 5 gf/cm², about 6 gf/cm², or any range defined between two of any of the forgoing values. Such separation force profile characteristics are larger than those exhibited by existing dry wipe systems (e.g., such as tissues), while the overlap distance (e.g., 5 to 50 mm) or overlap area characteristics are smaller than for existing dry wipe systems.

Such relatively small overlap distances still allow for various folding configurations, while providing a center pick point, and keeping an even stack of wipes (i.e., perimeter edges and sides of each wipe are aligned with one another). Exemplary folding or stacking patterns include the Z-Z-Z fold, as well as the Z-V-Z fold. Other folding or stacking patterns are also possible, e.g., including, but not limited to J folds, C folds, use of J folds or C folds in combination with Z folds or V folds, etc.

Providing a pick point (i.e., that location where the user pinches a lead edge of the lead wipe) centered within a width of the stack may be beneficial. In some embodiments, the pick point may also be centered relative to the length of the stack. A centered pick point allows for the pick point to align with a correspondingly centered orifice in the container body throughout use. The relatively small overlap of the tacky wipes enables the stack to have a uniform shape and size and still provide good dispensing. By uniform shape and size, it is meant that the edges and sides of each wipe of the stacked wipes are vertically aligned with one another so that the stack is uniform along its height. Examples of such uniform stacks are seen in FIGS. 4A-7B. In some embodiments, the pick point may vary slightly from a center point, e.g., so long as the lead edge of the lead wipe is vertically aligned relative to the dispensing orifice, so that it can still be grasped by the user inserting fingers vertically down into the interior 104. The substrates may stretch in one direction, stretch in two directions or have no stretch.

FIGS. 4A, 4B, and 4C schematically illustrate exemplary Z-Z-Z folding patterns where each wipe 108 includes two folds 130, so as to define 3 sections 108 a, 108 b, and 108 c. As seen in FIG. 4A, there may be an overlap distance 132 provided between a section of one wipe and a section of the next wipe, apparent as the wipes are unfolded from the stack. For example, FIG. 4A shows overlap between a part of section 108 a of a lead wipe and section 108 c of a following wipe. FIG. 4B shows a different overlap pattern, 132 a where section 108 a and a portion of section 108 b of a following wipe overlaps section 108 c and a portion of section 108 b of a lead wipe. FIG. 4C shows yet another overlap pattern 132 b, where section 108 c and a part of section 108 b of a lead wipe may overlap a part of section 108 a of a following wipe.

In the illustrated examples, the overlapping portion of one wipe may be that portion that is interleaved into the other wipe. For example, in illustrated examples 4B and 4C, the overlapping portion of one wipe may be considered as that portion inserted into the fold formed into the adjacent wipe. It will be apparent that any of various suitable folding and stacking patterns may be employed, which can be adapted to provide the desired overlap distance values of from about 5 mm to about 50 mm. In general, overlap values significantly greater than 50 mm are required to pop-up dispense in dry wipe applications such as the tissue industry. The slight tack of the wipe substrate in the present systems (e.g., where loaded with an adhesive, tacky binder) provides additional adhesion between wipes, so that a smaller overlap is sufficient to provide the desired pop-up dispensing. To great of an overlap may increase the adhesion too much, leading to roping or clumping.

FIG. 5A schematically illustrates an exemplary Z-V-Z folding pattern, in which one wipe 208 (resembling a V) includes a single fold 130, while another wipe 108 includes two folds 130, so as to resemble a Z. The Z and V configured wipes 108 and 208 alternate with one another within the stack of wipes, as shown. An overlap 132 is provided. FIG. 5B schematically illustrates another exemplary Z-V-Z folding pattern with wipes 208 folded into a V-shape (or perhaps more accurately a U-shape in FIG. 5B), interleaved with wipes 108 folded into a Z (or an S or backwards S) shape. To more easily differentiate between the differently configured wipes of FIGS. 5A and 5B, Z folded wipes 108 are shown in broken lines, the V (or U) folded wipes 208 being shown in solid lines.

FIG. 6A illustrates an exemplary J-fold of a single wipe 308, while FIG. 6B illustrates a plurality of such J-folded wipes 308 stacked atop one another. FIG. 7A illustrates an exemplary C-fold of a single wipe 408, while FIG. 7B illustrates a plurality of such C-folded wipes 408 stacked one atop another. In the stacks of FIGS. 6B and 7B, there may not technically be any interleaving of one wipe (i.e., the following wipe) into another wipe (i.e., the lead wipe). Rather, to achieve the desired overlap and resulting pop-up dispensing, adhesion of the following wipe to the lead wipe simply due to the lead wipe being stacked on top of the following wipe may be relied on. This may be sufficient to provide pop-up dispensing, particularly where the wipes are loaded with a tacky, adhesive binder, causing the wipes to exhibit tackiness and more adhesion one to another than would otherwise be the case (e.g., with completely dry wipes such as tissues).

The length of leading and/or trailing section 408 a or 408 b in FIG. 7A-7B (for a C-folded wipe) or leading section 308 a in FIG. 6A-6B (for a J-folded wipe) may be particularly configured in a manner similar to the overlapping portions 132 described above. This ensures that as the lead wipe is pulled through the dispensing orifice (e.g., orifice 106), the following wipe follows, with the connection between the lead and following wipe provided by the overlapping portion breaking just as the lead end of the following wipe begins to emerge through the delivery orifice. In other words, the overlapping portion of a C or J-folded wipe may be considered to be the appropriate leading or trailing section of that wipe, which section may overlap and adhere to the adjacent wipe as the lead wipe is pulled through the delivery orifice.

Such C and/or 3-folded wipes may be interleaved with one another, or with other folding patterns (e.g., C or 3 folded wipes interfolded with Z or V folded wipes). Various patents describing possibly suitable folding patterns include U.S. Pat. Nos. 6,045,002; 6,550,634; 6,960,349; PCT Publications WO 98/34781 and WO 00/30956, and Applicant's Earlier Docket No. 340.216, each of which is herein incorporated by reference in its entirety.

The substrates may have dimensions as desired. In an embodiment, the wipes are square or rectangular. For example, in an embodiment, the length and width dimensions may be from about 6 inches to about 12 inches, or from about 8 inches to about 11 inches. Exemplary dimensions include 8.7″×7″ and 10″×8.7″. Another factor that the inventors have found to be important in achieving the desired pop-up dispensing without roping, clumping, and without undesirable sticking of tacky wipes within the container is the ratio of the surface area of the wipe to the surface area of the dispensing orifice. This ratio may be from about 17.75:1 to 6:1, preferably from 11:1 to 6.75:1, more preferably from 9.8:1 to 8:1. Another characteristic ratio is the ratio of the surface area of the upper panel of the container to the surface area of the orifice. This ratio may be from about 9.9:1 to about 3.1:1, preferably from 6.2:1 to 3.75:1, and more preferably from 5.4:1 to 4.5:1. For the surface area ratios, the surface area of the upper panel includes the surface area of the orifice.

In one embodiment, the wipe (e.g., wipe 108) comprises a nonwoven fabric having a basis weight of less than about 60 gsm, from about 20 gsm to about 60 gsm, from about 30 gsm to about 60 gsm, or from about 40 gsm to about 60 gsm. The wipe may further include a plurality of apertures (e.g., a pattern embossed or otherwise formed therein). Such a pattern of apertures, particularly in combination with a tacky adhesive binder, make the wipe very effective for particle pick up (e.g., as a dusting wipe). In an embodiment, the fabric of the wipe may have at least about 125 apertures (e.g., from 125 to about 250 apertures) per square inch.

In an embodiment, the apertures may be slit-like. The apertures may be of other regular or irregular geometric formations or shapes, such as, but not limited to ovals, circles, rectangles, squares, diamonds, triangles, stars, crisscross shaped, and the like. The apertures may be arranged in a regular or irregular pattern along (machine direction) and/or across (cross machine direction) the fabric. As regular patterns, the apertures may be aligned in rows and columns at regular intervals, staggered, clustered, and so forth. In one embodiment, the apertured wipe or precursor thereto may be formed in accordance with the teachings of U.S. Pat. Nos. 2,862,251, and/or 8,257,818, each of which is hereby incorporated by reference.

The wipe substrate may preferably be a single layer, staple fiber substrate. Staple fiber lengths may typically be selected in the range of 0.25 inch to 8 inches, wherein a range of 1 to 3 inches may be typically preferred and the fiber denier may typically be selected in the range of 1 to 15. A range of 2 to 6 denier may typically be preferred for general applications.

Exemplary nonwoven fibers and/or staple fibers suitable for use with the present invention include natural fibers, synthetic fibers, and combinations thereof. Suitable natural fibers may include, but are not limited to, cellulosic fibers such as cotton, wood pulp, hemp, flax, viscose rayon, or combinations thereof. Synthetic fibers, which may be blended in whole or part, may include, but are not limited to, thermoplastic polymers, thermoset polymers, and combinations thereof. Thermoplastic polymers suitable for use may include, but are not limited to polyolefins, polyamides, polyesters, and combinations thereof. The thermoplastic polymers may be further selected from homopolymers, copolymers, conjugates, sheath-core structures, and other derivatives, including those thermoplastic polymers having incorporated therein melt additives, surface-active agents, etc.

In an embodiment, the wipe may employ 100% viscose rayon or other cellulosic staple fiber. In another embodiment, the substrate may be formed using a spunlace process to create a 50% polyethylene terephthalate (PET)/50% rayon (regenerated cellulose) blend.

Subsequent to forming an apertured substrate or precursor thereto, the substrate may be loaded with a desired material (e.g., a tacky adhesive binder). For example, an adhesive binder may be applied, e.g., printed, onto the wipe so as to bond discrete portions of the staple length fibers while retaining other portions of the staple length fibers in an unbonded state. The adhesive bonding step may include printing the adhesive onto the wipe in a regular or irregular pattern. The pattern may include any discontinuous pattern and is not intended to be a limiting factor of the present invention. The adhesive binder or other material may be kiss-coated or padded onto the wipe. In an embodiment, the binder or other material may be applied to both sides of the wipe. The adhesive binder may include, but is not limited to, latex, acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate, starch, polyvinyl chloride or combinations thereof. In one particular embodiment, the wipe may be prepared by hydraulically forming apertures in a carded web of staple fibers to entangle fiber filaments, which is then coated with a pressure sensitive binder.

The latex binder may be topically applied to at least one surface of the fabric so as to provide a total add-on amount to the fabric, on a solids basis, ranging from about 1 g/m² to about 25 g/m², or from about 10 g/m² to about 20 g/m², based on total weight of the finished wipe.

The pop-up dispensing systems of the present invention may comprise substantially dry, tacky nonwoven fabric wipes which may be used as disposable dusting and cleaning hand wipes. In addition the substrates may be disposable dusting and cleaning wipes that can be removably mounted on mop heads, dusters, abrasive cleaning tools, dust brushes and pans, and other suitable tools. Although not limited thereto, the tacky substantially dry wipes of the invention are particularly suitable as household dusting and cleaning wipes.

The examples and testing results that follow are intended to further illustrate exemplary embodiments of the invention. They are not intended to limit the scope of the invention.

Exemplary nonwoven substrates were converted on a Paper Converting Machine Company (PCMC) Clipper 300 using 8.7″ roll widths and Z-Z-Z folding ploughs. The interfolded substrates had an overlap distance between 5 mm and 50 mm. In alternative embodiments, the unfolded finished wipe dimensions were 8.7″×7″ and 10″×8.7″ and were converted on a PCMC Clipper 300. Different iterations are possible using Z-V-Z & Z-Z-Z fold patterns (with different overlap distances) and Z-V-Z folding patterns, even without interfolding. Other suitable fold patterns as described herein include C-C (without interfolding) and C-C-C-C folding option (hand folded).

Example 1

The nonwoven substrates were loaded with acrylic binder, DOW PRIMAL N-560J acrylic emulsion, which was applied at 18 g/m2. The moisture absorption and loss characteristics of the manufactured and binder loaded wipes were measured by leaving the wipes in an 80/80 humidity chamber for 1 week. After 1 week, the wipes were each weighed, then dried in an oven set to 105° C. for 3 hours, weighed, and then dried for another 3 hours (6 hours total dry time). Moisture loss for both the 3 hour and 6 hour times is shown in Tables 1A and 1B. As is apparent, no water is intentionally loaded within the wipes during manufacture. They showed a water absorption of up to about 3% by weight under the described storage conditions (80% humidity at 80° F.) after 1 week.

TABLE 1A After 3 hrs Initial Weight Final Weight Moisture Loss Percentage Sample (gm) (gm) (gm) Loss 1 1.789 1.739 0.05 2.79% 2 1.711 1.662 0.049 2.86% 3 2.005 1.946 0.059 2.94% 4 1.784 1.727 0.057 3.20% 5 1.761 1.708 0.053 3.01%

TABLE 1B After 6 hrs Initial Weight Final Weight Moisture Loss Percentage Sample (gm) (gm) (gm) Loss 1 1.789 1.741 0.048 2.68% 2 1.711 1.665 0.046 2.69% 3 2.005 1.948 0.057 2.84% 4 1.784 1.732 0.052 2.91% 5 1.761 1.705 0.056 3.18%

In order to measure the separation force of the manufactured wipes, the wipes were carefully unrolled, without separating the overlaps between wipes. The overlaps were measured. Every other overlap was then separated in order to test individual overlaps (two wipes) on an Instron machine, so as to measure separation force. Some of the wipes were cut in half (half width was 3.5 inches) in order to make sure that the measurement was repeatable. Whether the tested wipes were 3.5 inches in width, or the full 7 inches in width, once the width of the overlap multiplied by the length of the overlap was taken into account, the force over area calculations were found to be consistent. A variety of pull speeds for separating the overlapping wipes were also tested to ensure that the speed in pulling the wipes apart did not alter the separation force profile, and that the results were consistent.

Example 2

Overlapped material was tested on the Instron to understand the force required to separate two tacky, clinging wipes. The wipes were overlapped so as to pop-up dispense, were manufactured as described above with Z-Z-Z folding ploughs, and had initial dimensions of 8.7″×7″ for each wipe. The wipes were separated into pairs of two wipes, as described above, and then cut in half, so as to have a width of 3.5 inches. Twenty specimens were tested on the Instron machine, set at a pull speed of 5 in/min. The results are shown in Table 2.

TABLE 2 Maximum Load Overlap Sample (lbf) (mm) 1 0.1929 29 2 0.1905 29 3 0.1534 30 4 0.1629 30 5 0.1445 22 6 0.1471 22 7 0.1431 25 8 0.1407 25 9 0.1739 36 10 0.1683 36 11 0.1907 29 12 0.1912 29 13 0.1659 30 14 0.1589 30 15 0.1613 23 16 0.1471 23 17 0.1619 25 18 0.1653 25 19 0.1900 36 20 0.1824 36 Mean 0.1666 28.5 St. Dev. 0.0179 4.75 Maximum 0.1929 36 Minimum 0.1407 22

Example 3

Example 2 shows results for some of the 7 inch samples that were cut in half, to 3.5 inches in width. Example 3 shows results for more samples from the same production run. The results for Example 3, shown in Table 3, show that the testing is repeatable. The measured overlap values were measured through an entire stack of wipes in order to ensure wipes at the top and bottom of the stack in the container would exhibit similar separation force profile values. Pull speed was again set at 5 in/min.

TABLE 3 Maximum Load Overlap Sample (lbf) (mm) 1 0.1846 28 2 0.1955 28 3 0.1967 31 4 0.1910 31 5 0.1719 20 6 0.1681 20 7 0.2089 25 8 0.1974 25 9 0.1841 36 10 0.1966 36 11 0.2084 28 12 0.1966 28 13 0.1865 31 14 0.1578 31 15 0.1674 19 16 0.1635 19 17 0.2030 26 18 0.2094 26 19 0.2094 36 20 0.1772 36 Mean 0.1887 28 St. Dev. 0.0164 5.66 Maximum 0.2094 36 Minimum 0.1578 19

Example 4

A new and different production run of fabric material was tested to understand any variability that may exist between different production runs, as well as differences due to storage time within the container. In addition, the environmental conditions between the two trials were observed to be quite different, where higher humidity present during the new production run caused some difficulty in manufacturing. The wipes were again separated, the overlaps measured, and the wipes cut to half width (3.5 inches) for testing under the same conditions. Pull speed was again set at 5 in/min. The results are shown in Table 4.

TABLE 4 Maximum Load Overlap Sample (lbf) (mm) 1 0.1085 31 2 0.0938 31 3 0.1376 19 4 0.1330 19 5 0.1194 18 6 0.1324 18 7 0.1229 22 8 0.1410 22 9 0.1571 26 10 0.1185 26 11 0.1167 16 12 0.1549 16 13 0.1575 22 14 0.0542 22 15 0.0615 7 16 0.1296 7 17 0.1220 28 Mean 0.1141 21 St. Dev. 0.0415 6.95 Maximum 0.1575 31 Minimum 0.0073 7

Example 5

Wipes from the same production run as Example 4 were tested at their full width (7 inches). The increased width of the tested samples exhibited correspondingly higher maximum load values. Pull speed was again set at 5 in/min. The results are shown in Table 5.

TABLE 5 Maximum Load Overlap Sample (lbf) (mm) 1 0.2715 30 2 0.2648 19 3 0.2286 18 4 0.2071 25 5 0.2429 27 6 0.1983 15 7 0.2658 21 8 0.0982 7 9 0.1407 13 Mean 0.1904 19.4 St. Dev. 0.0914 7.25 Maximum 0.2715 30 Minimum 0.0143 7

Example 6

Wipes from the same production run as Examples 4-5 were again tested at their full width (7 inches), but at a different pull speed (30 in/min) to ensure that the test results were not dependent on pull speed. The results are shown in Table 6.

TABLE 6 Maximum Load Overlap Sample (lbf) (mm) 1 0.2853 6 2 0.2947 13 3 0.4759 28 4 0.4474 28 5 0.3585 21 6 0.4362 29 7 0.2215 14 8 0.3219 11 9 0.3819 28 10  0.3873 32 Mean 0.3611 21 St. Dev. 0.0807 9.25 Maximum 0.4759 32 Minimum 0.2215 6

Example 7

The test results show such a structure with increased texture and lower binder addition (14 gsm compared to 18 gsm), which exhibited less cross machine direction stretch, may be somewhat more independent of overlap distance, but the lbf/area separation force profile values are still within the same general range. The tested wipes were cut to half width (3.5 inches), and tested at a pull speed of 5 in/min. The results are shown in Table 7.

TABLE 7 Maximum Load Overlap Sample (lbf) (mm) 1 0.1825 17 2 0.1863 17 3 0.1822 28 4 0.1717 28 5 0.1967 29 6 0.1840 29 7 0.2119 32 8 0.2106 32 9 0.1717 50 10 0.1955 50 11 0.1843 32 12 0.2032 32 13 0.1620 22 14 0.1862 22 15 0.2058 26 16 0.2328 26 Mean 0.3611 29.5 St. Dev. 0.0807 9.38 Maximum 0.4759 50 Minimum 0.2215 17

Example 8

Wipes from the same production run as Example 7 were tested at their full width (7 inches), with the pull speed also at 5 in/min. The results are shown in Table 8.

TABLE 8 Maximum Load Overlap Sample (lbf) (mm) 1 0.5025 24 2 0.2636 28 3 0.3143 23 4 0.3607 25 5 0.3912 22 6 0.5158 47 7 0.1129 48 8 0.3121 23 9 0.3293 24 10  0.3359 22 Mean 0.3611 28.6 St. Dev. 0.0807 10.11 Maximum 0.4759 48 Minimum 0.2215 22

Example 9

Wipes of a larger size (8.7 in×10 in rather than 8.7 in×7 in) were tested at their full width (8.7 inches), with the pull speed also set at 5 in/min. Overlap distances were not measured in Example 9. The results are shown in Table 9.

TABLE 9 Maximum Load Sample (lbf) 1 0.1649 2 0.2205 3 0.2013 4 0.1519 5 0.2661 6 0.2288 7 0.1842 8 0.2646 9 0.2584 10  0.2570 11  0.3217 12  0.1897 Mean 0.3611 St. Dev. 0.0807 Maximum 0.4759 Minimum 0.2215

Example 10

Wipes of the same larger size (10 in×8.7) as in Example 9 were tested at their full width (8.7 inches), with the pull speed set at 30 in/min. The results are shown in Table 10.

TABLE 10 Maximum Load Overlap Sample (lbf) (mm) 1 0.3796 34 2 0.3857 36 3 0.3414 29 4 0.5024 32 5 0.3469 20 6 0.2162 18 7 0.4123 37 8 0.4553 56 9 0.4719 41 10 0.5476 41 11 0.3290 20 Mean 0.3705 28.6 St. Dev. 0.1324 10.11 Maximum 0.5476 48 Minimum 0.0580 22

Example 11

To validate the previously seen results (see Example 6), another batch of 7 inch wide wipes were tested at their full width, with the pull speed set at 30 in/min. The results are shown in Table 11.

TABLE 11 Maximum Load Overlap Sample (lbf) (mm) 1 0.2897 22 2 0.3782 31 3 0.4461 39 4 0.0834 23 5 0.4070 32 6 0.5994 38 7 0.5531 24 8 0.4935 31 9 0.6467 38 10  0.6320 Mean 0.3705 30.9 St. Dev. 0.1324 6.68 Maximum 0.5476 39 Minimum 0.0580 22

The force values were plotted against overlap values, showing a trend where larger overlaps also have larger force to separation values. The data indicates a positive correlation between maximum load (lbf) and overlap distance. The tested substrate that exhibited relatively less stretch in the cross machine direction (Example 7) appeared to not be as affected by overlap distance. The data was split into two graphs—one for 3.5 inch half width strips and another for full width 7 inch strips. Although the groups exhibit different maximum load (lbf) characteristics, when overlap area is taken into account, the data is normalized. The results of such plotting are shown in FIGS. 8A-8B.

The overlap area may be calculated as length of the overlap multiplied by the width of the tested wipe, accounting for total contact area between the two wipes. FIG. 9 plots the results of maximum load per area (in gf/cm²) against overlap. This maximum load per area value is also referred to herein as the separation force profile. To convert lbf to gf, there are 453.6 gf/lbf. As seen, the separation force profiles for the tested wipes generally lie between 1 gf/cm² and 6 gf/cm², regardless of wipe size, testing size, or pull speed.

Example 12

In addition to measuring the force separation profile (gf/cm²) to separate two wipes, the force profile over time (or extension) was also measured as a wipe is dispensed (e.g., pulled) through the dispensing orifice of the container body. For this test, the container box was attached to the bottom clamp of the Instron machine, and the wipe to be dispensed was attached to the top clamp. Speed was set at 15 in/min with the top clamp moving upward and dispensing the wipe. As seen in FIG. 10, the force profile for these wipes is significantly different from that of a dry wipe (e.g., tissue) or a wet wipe (e.g., baby wipe). The force profile includes two distinct peaks. The first peak is associated with pulling of the lead end of the lead wipe through the dispensing orifice, which peak is followed by a decrease in force where the wipe is folded (i.e., force drops as this fold is simply unfolded), followed by another peak to separate the lead wipe from the following wipe. The two folds of such a Z fold pattern wipe is also reflected in the force plot of FIG. 10.

Example 13

Example 13 was conducted to better understand how the dispensing experience changes when changing the surface area or shape of the dispensing orifice of the paperboard carton. Each of 5 dispensing orifices was tested 3 times, each with 20 wipes. The term “fallbacks” refers to the number of times the following wipe fell back into the carton when the lead wipe ahead of it was dispensed. The term “clumps” refers to the number of instances where more than one wipe would come out of the carton at a time. In each tested sample, the final 2-4 wipes would clump together, although with at least some of the tested samples, clumps would form earlier in dispensing the entire stack as well, as shown in Table 12. Sample 3 shows the best results, and included a generally diamond shaped orifice such as that seen in FIG. 1. Samples 1, 2, 4, and 5 included generally rectangular shaped orifices (e.g., similar to FIG. 3B). The results are shown in Table 12.

TABLE 12 Number of Ratio of Size Surface Area Wipes in Sample to Sample 3 (cm²) Fallbacks Clumps Last Clump 1 0.5 22 3 3 2 2 0.8 35 2 3 2 3 1 44 1 1 2 4 1.3 58 2 4 4 5 1.6 70 4 4 4

Although principally described in the context of wipes for use in dusting with good particle pick up performance, including a tacky, adhesive binder loaded on or within the wipe, it will be appreciated that the dispensing systems may also be suitable for use in other applications where a substrate is loaded with a material, such as dryer sheets (e.g., loaded with fabric softener). Such substrates may also be substantially dry to the touch.

Without departing from the spirit and scope of this invention, one of ordinary skill can make various changes and modifications to the invention to adapt it to various usages and conditions. As such, these changes and modifications are properly, equitably, and intended to be, within the full range of equivalence of the following claims. 

1. A pop-up dispensing system for dispensing substantially dry substrates, the system comprising: (a) a container including a container body forming an interior region; (b) a plurality of stacked substantially dry substrates disposed within the interior region of the container, the stacked substrates being coated or impregnated; (b) a dispensing orifice defined through an upper panel of the container body through which a lead substrate of the plurality of stacked substantially dry substrates can be pulled; (c) wherein the dispensing orifice has a cross-sectional area from 22 cm² to 75 cm² and the stacked substrates are stacked in a manner to exhibit a separation force profile of the lead substrate from a following substrate of from 1 gf/cm² to 6 gf/cm².
 2. The pop-up dispensing system of claim 1, wherein dispensing orifice is diamond shaped in which the corners of the diamond are rounded to better facilitate insertion of a user's fingers through the dispensing orifice to retrieve the lead substrate.
 3. The pop-up dispensing system of claim 1, wherein the stacked substrates are interfolded with one another in a manner such that pulling on a lead end of a lead substrate of the plurality of stacked substrates causes a following substrate of the plurality of substrates to also be pulled and follow the lead substrate.
 4. The pop-up dispensing system of claim 3, wherein the following substrate has an overlap distance relative to the lead substrate of from 5 mm to 50 mm.
 5. The pop-up dispensing system of claim 1, wherein the dispensing orifice has a cross-sectional area from 22 cm² to 70 cm².
 6. The pop-up dispensing system of claim 1, wherein the dispensing orifice has a cross-sectional area from 35 cm² to 58 cm².
 7. The pop-up dispensing system of claim 1, wherein the dispensing orifice has a cross-sectional area from 40 cm² to 48 cm².
 8. The pop-up dispensing system of claim 1, wherein edges and sides of each substrate of the stacked substrates are vertically aligned with one another so that the stack is uniform.
 9. The pop-up dispensing system of claim 1, wherein each wipe of the stacked substrates has a center pick point, being disposed so that a leading edge of each substrate is vertically aligned with the dispensing orifice.
 10. The pop-up dispensing system of claim 1, wherein the pop-up dispensing system is for dispensing substantially dry wipes, the plurality of stacked substantially dry substrates comprising substantially dry wipes.
 11. The pop-up dispensing system of claim 10, wherein the substantially dry wipes are coated or impregnated with a tacky adhesive binder, selected from the group consisting of: latex, acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate, starch, polyvinyl chloride or combinations thereof.
 12. The pop-up dispensing system of claim 11, wherein each wipe comprises a nonwoven substrate having a plurality of apertures, the substrate having a basis weight of not more than 60 g/m² and an aperture density of at least 125 apertures/in² of substrate.
 13. The pop-up dispensing system of claim 3, wherein the lead substrate pulls on the following substrate as it goes through the dispensing orifice so that it is substantially flat when the lead substrate is separated from the following substrate.
 14. The pop-up dispensing system of claim 11, wherein the tacky adhesive binder comprises a binder selected from the group consisting of latex, acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate, starch, polyvinyl chloride and combinations thereof.
 15. The pop-up dispensing system of claim 11, wherein the binder is applied to a surface of the wipe on a solids basis of from 1 g/m² to 25 g/m².
 16. The pop-up dispensing system of claim 11, wherein the container is rectangular and includes a folding cover panel different from the upper panel, the cover panel folding over the dispensing orifice of the upper panel, acting as a lid so as to protect the wipes during storage.
 17. The pop-up dispensing system of claim 1, wherein a ratio of a surface area of each substrate to a cross-sectional area of the dispensing orifice is from 17.75 to
 6. 18. The pop-up dispensing system of claim 1, wherein a ratio of a surface area of the upper panel to a cross-sectional area of the dispensing orifice is from 9.9 to 3.1.
 19. A pop-up dispensing system for dispensing substantially dry, tacky wipes, the system comprising: (b) a container including a container body forming an interior region; (b) a plurality of stacked substantially dry, tacky wipes, the stacked wipes being coated or impregnated with a tacky adhesive binder selected from the group consisting of: latex, acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate, starch, polyvinyl chloride or combinations thereof, the stacked wipes being disposed within the interior region of the container in a manner such that pulling on a lead end of a lead wipe of the plurality of stacked wipes causes a following wipe of the plurality of wipes to also be pulled and follow the lead wipe; (b) a dispensing orifice defined through an upper panel of the container body through which the lead wipe of the plurality of stacked substantially dry, tacky wipes can be pulled; (c) wherein the dispensing orifice has a cross-sectional area from 22 cm² to 75 cm²; (d) the stacked wipes are stacked in a manner to exhibit a separation force profile of the lead wipe from the following wipe of from 1 gf/cm² to 6 gf/cm²; and (e) each wipe has an overlap distance relative a corresponding adjacent wipe of from 5 mm to 50 mm.
 20. A pop-up dispensing system for dispensing substantially dry, tacky wipes, the system comprising: (a) a container including a container body forming an interior region; (b) a plurality of stacked substantially dry, tacky wipes, the stacked wipes being coated or impregnated with a tacky adhesive binder, the stacked wipes being interfolded with one another within the interior region in a manner such that pulling on a lead end of a lead wipe of the plurality of stacked wipes causes a following wipe of the plurality of wipes to also be pulled and follow the lead wipe; (b) a generally diamond shaped dispensing orifice defined through an upper panel of the container body through which the lead wipe of the plurality of stacked substantially dry, tacky wipes can be pulled, in which the corners of the diamond are rounded to better facilitate insertion of a user's fingers through the dispensing orifice to retrieve the lead wipe; (c) the wipes being stacked so that each wipe has a center pick point, so that the lead end of each wipe is vertically aligned below the dispensing orifice; (d) wherein the dispensing orifice has a cross-sectional area from 22 cm² to 75 cm²; (e) the stacked wipes being stacked in a manner to exhibit a separation force profile of the lead wipe from the following wipe of from 1 gf/cm² to 6 gf/cm²; and (f) each wipe has an overlap distance relative a corresponding adjacent wipe of from 5 mm to 50 mm. 